Panel

ABSTRACT

The present invention relates to panels, panel systems and panel sealing elements, and may be useful for panels used in building. The invention may be particularly useful for panels used on existing walls to provide a desired structural appearance or effect. According to an aspect, the present invention provides a panel for providing a selected structural appearance, the panel comprising a support layer formed from a rigid material, an outer layer comprising elements which provide the selected structural appearance, the outer layer formed from a material different from the support layer material, and a mid-layer between the support layer and the outer layer, wherein the mid-layer allows for different thermal expansion and contraction rates of the support layer material and the outer layer material.

FIELD

The present invention relates to panels, panel systems and panel sealingelements, and may be useful for panels used in building. The inventionmay be particularly useful for panels used on existing walls to providea desired structural appearance or effect.

BACKGROUND

Panels are used in building to provide a structural appearance oreffect, for example, a weather board wall can be made to look like abrick wall by attaching panels having a brick or brick-like appearanceor effect. Such panels may have a substrate onto which there is attacheda number of brick or brick-like elements which are arranged to resemblea laid brick wall. In other examples, the appearance or effect may befor a regular or irregular stone wall, or other types of wall structure.Other types of panels may have a structural appearance or effect printedon them, or represented some other way. Often the structural appearanceor effect can seem artificial as the material used for appearance oreffect or the technique of applying the material can be inferior. Anartificial looking appearance or effect is undesirable as many peoplewant to have something closely approximating the real appearance of aparticular structure.

Such panels are typically regularly shaped, for example, squarely orrectangularly shaped, to allow a number of panels to be readily usedtogether to cover a wall surface. The panels abut each other so as totry to form a continuous structural pattern. However, the seams betweeneach of the panels are usually readily visible so that the appearance oreffect is negatively impaired. This may be particularly problematicwhere the structural appearance or effect is for a brick pattern, forexample, an alternating off-set row pattern, such as a stretcher bondlaid brick pattern. At the juncture of two half bricks along the seam,there will be an appearance of a “split” brick.

A similar problem arises where the panels meet at a corner. For example,the corner bricks will appear as if they have a “split” due to the seambetween a panel on the wall on one side adjacent the corner and anotherpanel on the wall on the other side adjacent the corner. The splitappearance can worsen with time, as the gap along the seam can widen orbecome uneven.

Another problem with existing panels is that the substrate and theelements making the structural appearance or effect have differentthermal expansion and contraction rates. The substrate may be subject tofaster expansion in hot conditions, or may be subject to greater overallexpansion in such conditions than the structural elements. Conversely,the substrate may be subject to faster contraction in cold conditions,or may be subject to greater overall contraction in such conditions thanthe structural elements. This can lead to cracking and other failures inthe panels.

A further problem with existing panels is a lack of structuralintegrity, or a weak attachment to the wall. In harsh weatherconditions, such as very high winds, the panels can snap, delaminate,bend, or become partially or fully detached from the wall. This lack ofstructural integrity can be due to inferior materials, or inferiorstructure of materials. The detachment from the wall may be due to poorattachment mechanisms, poor adhesive, or adhesive being poorly appliedto the panels.

Some existing panels have tried to solve problems with strength by usingstronger materials, but this may unacceptably increase the weight ofsuch panels, thus limiting their use in many circumstances.

Some methods of attaching panels have problems, including lack ofstrength and/or durability. Some attachment methods can be difficult touse, unreliable or messy. Further, the existing attachment methods mayhave the problem that the panels are subject to reproducing defects inthe wall to which they are attached. Such defects include unevenness ofthe wall surface or curvature. The panels are attached to the wall usingmeans that are independent of attachment means for others of the panels.This results in the panels being subject to local defects in the wall.This can cause the panel to be misaligned from other adjacent panels.Where the wall has sufficiently localized curvature, the panels may alsorepeat this defect, and this can also cause misalignment.

Yet another problem in existing panels is the inability to choose analternative appearance for the structural appearance or effect in agiven panel. The panels will be provided in a given colour and pattern,but this colour and pattern is not alterable by a user at time ofinstallation. This can be limiting where it is desired to have new andvaried structural appearances or effects where using a given panel.

Other problems with some existing panels include flammability (or lackof ability to retard fire), colour fading, corrosion, lack of resistanceto scratching, lack of resistance to impact damage, and lack ofresistance to other physical damage, lack of flexibility (notappropriate for areas prone to seismic activity or high wind), or toomuch flexibility (these panels have a tendency to bend in high windconditions, and do not provide any structural strengthening to a wall),along with other structural and aesthetic defects and shortcomings.

Further problems exist with panel systems, for example panel systems forforming wall structures in buildings, where the seals between the panelsin the structure are prone to leak when subjected to precipitation, orare not sufficiently wind-tight, and therefore cannot provide adequatewind protection. Moreover, unsealed or inadequately sealed panels maynot provide thermal and/or sound insulation, which may be required inareas where a building is located, such as particularly hot or coldareas, or areas subject to a lot of noise.

Previously, panels used, for example, to form structures in buildings,may have seals between those panels which are obvious to an observerwhen the panels have been installed. Such obvious seals between panelsmay create an unacceptable and unsightly appearance to a building. Itmay therefore be desirable to have a sealing system, suitable forpanels, which allows for panels to be adequately sealed for protectionagainst, for example, precipitation, wind, thermal leaking, and noise,and wherein the sealing system for the panels is not obvious to anobserver looking at the installed panel system.

There is a need to overcome, or at least ameliorate, at least one of theabove-mentioned problems in the prior art, and/or to overcome, or atleast ameliorate, at least one problem in the prior art, which has notbeen mentioned above and/or to provide at least useful alternative toprior art devices, systems and/or methods.

BRIEF SUMMARY OF THE INVENTION

According to an aspect, the present invention provides a panel forproviding a selected structural appearance, the panel comprising asupport layer formed from a rigid material, an outer layer comprisingelements which provide the selected structural appearance, the outerlayer formed from a material different from the support layer material,and a mid-layer between the support layer and the outer layer, whereinthe mid-layer allows for different thermal expansion and contractionrates of the support layer material and the outer layer material.

In an embodiment, the support layer includes a honeycomb substrate and abacking sheet for the honeycomb substrate.

In an embodiment, the backing sheet and honeycomb substrate are formedfrom aluminum.

In an embodiment, the mid-layer includes a fiberglass sheet.

In an embodiment, the mid-layer includes an aluminum sheet.

In an embodiment, the selected structural appearance comprises aplurality of regular shaped elements having a periodic tessellatedpattern.

In an embodiment, the elements are rectangular brick-like shapes and thepattern comprises an alternating off-set row brick pattern.

In an embodiment, the pattern comprises a brick stretcher bond pattern.

In an embodiment, two opposing sides of the panel comprise complementarytoothed shapes such that, when one panel is placed next to another likepanel the shape of adjacent sides of the panels form a finger joint toprovide a continued alternating off-set row brick pattern.

In an embodiment, the panel is configured so that the finger jointcomprises a gap, wherein the gap is adapted to be fillable to produce agrout-like or mortar-like line.

In an embodiment, the grout-like or mortar-like lines comprise apolymer.

According to an aspect, the present invention provides a panel includingat least a support layer and an outer layer comprising elements whichprovide a selected structural appearance, the selected structuralappearance comprising a plurality of regular shaped elements having aperiodic tessellated pattern, a first side of the panel comprises atleast one row where, at least a part of an end element of the rowprotrudes outwardly, and at a second side of the panel opposite thefirst side, an end element of the row forms a part element space, suchthat, when two panels are to be placed side-by-side, the protruding endelement of one panel is to be placed in the corresponding part elementspace of the other panel.

In an embodiment, alternating rows of elements include at least a partof an end element of each row protruding outwardly of the first side,and an end element of each row forming a part element space, wherein atthe first side of the panel the support layer is shaped to correspondwith the end elements of each row.

According to an aspect, the present invention provides a panel systemincluding at least a first panel and a second panel each configuredaccording to the panel of paragraph [0026], wherein the first panel andsecond panel are placed side-by-side such that the protruding endelement of one panel is to be placed in the corresponding part elementspace of the other panel to form a finger joint.

In an embodiment, the first panel is a wall panel and the second panelis an adjacent wall panel.

In an embodiment, the first panel is a wall panel and the second panelis a corner piece for use at a junction between two walls, the cornerpiece being configured similarly to said first wall panel in that thecorner piece also includes at least a support layer and an outer layercomprising elements which provide the selected structural appearance ofa plurality of regular shaped elements having a periodic tessellatedpattern.

According to an aspect, the present invention provides a panel includingat least a support layer and an outer layer comprising elements whichprovide a selected structural appearance, the selected structuralappearance comprising a plurality of regular shaped elements having aperiodic tessellated pattern, wherein alternating rows of elementsinclude at least a part of an end element of each row protrudingoutwardly of the first side, and an end element of each row forming apart element space, wherein the support layer includes a straight sideedge along at least one side of the panel which is aligned with an outeredge of the end elements that protrude outwardly of the side, therebyexposing the support layer in each of the part element spaces.

In an embodiment, when two panels are to be placed side-by-side so as tocause abutment between the straight side edge of each panel, endelements in alternate rows of each panel form two adjacent part elementspaces to accommodate a separate element which substantially correspondsto the size and shape of the adjacent part element spaces such that theseparate element spans across adjacent panels when affixed to theexposed support layer.

In an embodiment, a first side of the panel includes the support layerhaving a straight side edge aligned with an outer edge of the endelements that protrude outwardly of the first side, and a second side ofthe panel includes a support layer having a straight side edge alignedwith an outer edge of the end elements that form a part element spacesuch that the end elements which protrude outwardly of the second sideprotrude beyond the support layer straight side edge.

According to an aspect, the present invention provides a panel systemincluding at least a first panel and a second panel each configuredaccording to the panel of paragraph [0031], wherein the first panel andsecond panel are placed side-by-side to cause abutment between thesupport layer straight side edge of each panel.

In an embodiment, one or more separate elements for affixing to theexposed support layer across the adjacent first and second panels.

In an embodiment, the first panel is a wall panel and the second panelis an adjacent wall panel.

In an embodiment, the first panel is a wall panel and the second panelis a corner piece for use at a junction between two walls, the cornerpiece being configured similarly to said first wall panel in that thecorner piece also includes at least a support layer and an outer layercomprising elements which provide the selected structural appearance ofa plurality of regular shaped elements having a periodic tessellatedpattern.

According to an aspect, the present invention provides a panel systemincluding at least a first panel and a second panel each panelconfigured according to the panel of paragraph [0032], wherein the firstpanel and second panel are placed side-by-side such that the protrudingend element of one panel that extends beyond the support layer straightside edge is to be placed in the corresponding part element space of theother panel and affixed to the exposed support layer to form a fingerjoint.

In an embodiment, the first panel is a wall panel and the second panelis an adjacent wall panel.

In an embodiment, the first panel is a wall panel and the second panelis a corner piece for use at a junction between two walls, the cornerpiece being configured similarly to said first wall panel in that thecorner piece also includes at least a support layer and an outer layercomprising elements which provide the selected structural appearance ofa plurality of regular shaped elements having a periodic tessellatedpattern.

In an embodiment, the pattern includes a grout-like or mortar-like linebetween each of the elements.

In an embodiment, the grout-like or mortar-like lines comprise apolymer.

In an embodiment, the panel system according to each of the aboveaspects comprises one or more rails for attachment to a surface to bepanelled, wherein the panels include clips for attachment to the one ormore rails.

In an embodiment, if the surface is a substantially vertical wall, theone or more rails are attached horizontally to the surface.

In an embodiment, the panel system further includes one or more backerrods for placement between adjacent panels, the backer rods having ashape and size to maintain a selected separation between the adjacentpanels.

In an embodiment, the panel according to each of the above aspectsincluding a mid-layer which allows for different thermal expansion andcontraction rates of the support layer material and the outer layermaterial.

According to an aspect, the present invention provides a sealing elementadapted to be fixed to at least one side of an object, and so as topresent a sealing surface outwardly facing with respect to the object,wherein the sealing surface has a periodic non-planar shape.

In an embodiment, the periodic non-planar shape is a sinusoidal orsinusoidal-like curved shape.

In an embodiment, the sinusoidal or sinusoidal-like curved shapeincludes more than half of one sinusoidal or sinusoidal-like cycle.

In an embodiment, the sealing surface is adapted to meet with acorresponding sealing surface of at least one other sealing element toform a seal.

In an embodiment, the object is a panel adapted to be used with otherlike panels to form a structure.

In an embodiment, a bracket for fixing the sealing element to an object.

In an embodiment, the bracket is elongate and has an L-shapecross-section.

In an embodiment, the object is a panel adapted to be used with otherlike panels to form a structure, each panel including an elongated edgeto which the L-Shaped bracket is to be attached.

In an embodiment, at least a part of the sealing element is formed froma rubber or rubber-like compound.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention and to show how it may beperformed, embodiments thereof will now be described, by way ofnon-limiting examples only and with reference to the drawings in which:

FIG. 1 is a perspective view of a part of a panel according to anembodiment of the present invention, a mid-layer and outer layer areshown as cut away to more clearly reveal the structure of the panel;

FIG. 2 is a perspective view of a panel attached to a wall, along with acorner piece, the panel and corner piece forming an embodiment of one asaspect of the present invention;

FIG. 3 is a similar view to FIG. 2 showing the corner piece joined tothe panel;

FIG. 4 is a rear perspective view of a panel including clips accordingto an embodiment of the present invention;

FIG. 5 is a side cross-sectional view of two panels configured as perthe panel of FIG. 1 attached to a wall with rails mounted, the panelsforming an embodiment of one as aspect of a system of the presentinvention;

FIG. 6 is a perspective view of FIG. 5 of two panels joined and mountedon a wall;

FIG. 7 is a perspective view of two panels each configured according toan embodiment, joined and using a separate element to fill spaces in theouter layer of the joined panels;

FIG. 8 is a perspective view of another embodiment of a corner piece ina panel system;

FIG. 9 is a detailed perspective view of the part of FIG. 8 circled in adashed line and labelled nine (9);

FIG. 10 is a perspective view of another embodiment of a panel of thepresent invention;

FIG. 11 is a side elevation view of a part panel and a full panelconfigured as per the panel of FIG. 10 and a corner configured as perthe corner of FIG. 8, in an embodiment of an aspect of a system of thepresent invention;

FIG. 12 is a rear side elevation view of a panel in accordance with anembodiment of the present invention;

FIG. 13 is a side cross-sectional view of two vertically disposed panelsincluding a sealing element in accordance with an embodiment of thepresent invention for sealing objects; and

FIG. 14 is a perspective and partial cross-sectional view of corneredges of two sealed panels configured as per the panels in FIG. 13.

DETAILED DESCRIPTION OF THE EMBODIMENT(S) OF THE INVENTION

For a better understanding of the invention it will now be described insome of its aspects and embodiments. This detailed description isintended to be non-limiting, and there are other aspects and embodimentswhich fall within the scope of the invention defined in the claims.

FIG. 1 shows a part of a panel 10 according to an embodiment including asupport layer 12, a mid-layer 14 and an outer layer 16. The supportlayer may include a rigid material comprising a honeycomb patternedsubstrate 22, which may be made from a metal such as aluminum.Advantages of using aluminum include it being light weight andnon-corrosive. It is to be understood that whilst reference is made to a“layer” throughout this document, any one of the support layer 12,mid-layer 14 and outer layer 16 may themselves comprise two or morelayers or sub-layers. For example, the honeycomb substrate 22 may have abacking sheet 23 which together with the substrate 22 forms the supportlayer 12. In one embodiment, the panel 10 includes a 1.0 mm anodizedsheet of aluminum 23 as a backing, on the back face of the honeycomb 22.

The honeycomb structure 22 allows the support layer 12 to be rigid. Itwill be understood that the rigidity is sufficient to support the panel10 with its layers, but the rigidity is limited so that the supportlayer has some flexibility in circumstances such as when the panel is ina high speed and variable direction wind. It will also be understoodthat the rigidity can be selectively altered by varying the structure ofthe panel, such as using a thicker honeycomb substrate or using a morerigid material to form same.

The outer layer 16 comprises the selected structural appearance, which,in this embodiment, is a brick wall having off-set alternating rows,also known as a stretcher bond brick laying pattern. The brick wallincludes brick elements 18, which may be formed from various materials.

In this embodiment, the brick elements 18 are formed from a porcelain orceramic type material. In other embodiments, the bricks elements 18 maybe formed from a material more closely resembling real bricks, such asbaked clay. In yet other embodiments, different structural appearancesor effects can be achieved by using real or artificial sandstoneelements, so as to resemble a dressed sandstone wall. It is alsopossible to use irregularly shaped materials such as stone or the liketo produce the effect of rustic constructions.

In different weather conditions, the panels will be subject to hot andcold conditions, and transitions between the two temperature extremes.It will be understood that an aluminum substrate 22 in the support layer12 and a ceramic or porcelain brick-like element 18 in the outer layer16 will have different rates of expansion or contraction in hot or coldconditions. The present invention provides a mid-layer 14 to negate orameliorate the effects of this differential expansion and contractionbetween the support layer 12 and the outer layer 16. In an embodiment,the mid-layer 14 may be formed from fiberglass in the form of afiberglass sheet. In an alternate embodiment, the mid-layer 14 may beformed from an additional sheet of metal (not shown), such as aluminium,which together with the aluminium backing sheet encloses the honeycombsubstrate 23 in a sandwich configuration. Due to its physicalproperties, the fiberglass sheet will stop or substantially lessen therisk of cracking of the outer layer elements 18 due to a more rapidexpansion in the aluminum substrate 22 of the support layer 12 in hot orincreasing temperature weather conditions. Accordingly, the fibreglasssheet is appropriate as a middle layer 14 when the panel is used inwarmer outdoor environments. In indoor environments, it may besufficient to use an additional aluminum sheet (not shown) in the middlelayer 14, in place of the fibreglass, as an aluminium sheet (on its ownor in combination with the substrate) will still allow for differentthermal expansion and contraction rates of the support layer materialand the outer layer material. The present invention is not limited tothe use of any one particular material in the middle layer 14, or in anyof the support or outer panel layers for that matter.

The elements 18 of the outer layer 16 have gaps between them, which maybe filled with a polymer 20 to mimic the appearance of grout or mortar.The grout-like or mortar-like effect can be achieved with a polymersubstance. The polymer has the added benefit that it can maintainelasticity when cured, and this elasticity allows for a certain amountof expansion and contraction between the elements and also assists withnegating or ameliorating the effect of differential expansion betweenthe outer layer 16 and the support layer 12.

In one technique of manufacturing a panel 10 according to theembodiment, the porcelain brick elements 18 are directly adhered to themiddle layer sheet 14 using an epoxy under an industrial vacuum tablefor a minimum of four hours and up to eight hours, depending onenvironmental conditions and temperature. In some embodiments, themiddle layer sheet 14 is already bonded to the honeycomb substrate 22before the brick elements 18 are attached to it.

Although the invention may have a considerable number of variations andchanges without effecting its essential nature, it has been found thatusing different backing panels instead of the aluminium honeycomb 22 mayresult in a lower performance rating for the impact and flexuralstrength. It has also been found that use of porcelain for thebrick-like elements provides a superior performance over stone ormasonry brick, as the porcelain is less subject to fading, discolouring,or an inconsistent colour range between the elements.

Furthermore, it has been found that using traditional grout or mortarresults in cracking and inconsistent coverage in the spaces between theelements 18 of the outer layer 16. Using the polymer mortar-like orgrout-like substance 20 provides a superior performance in changeableweather condition and makes for easier manufacture, and is less likelyto be damaged during transportation of panels from manufacture toinstallation.

Although there may be a number of adhesives to be used in bonding theporcelain brick to the fiberglass sheet, it has been found that an epoxyadhesive provides superior performance.

Further advantages of panels in accordance with the invention and itsembodiments are easier installation as the panels are significantlylighter than other panelling/cladding options. Lighter panels alsocontribute to a reduction in cost for transportation. The panels have ahigh impact rating and have been tested to Miami-Dade Notice ofAcceptance (NOA) and High Velocity Hurricane Zone (HVHZ) ratings. Otheradvantages are that the porcelain used for the brick elements 18 isresistant to fading and staining. The porcelain is also graffitiresistant.

As mentioned above, the panels are rigid, but have sufficientflexibility so that they can be used in areas with regular and/or highseismic activity. The flexibility also allows for the panels to be madein larger sizes. This cuts down on installation costs as more area canbe covered more quickly. The flexibility also allows for a high windload capability.

Furthermore, due to the materials being used in such an embodiments, thepanels are resistant to rust and corrosion. Moreover, the panels aresuitable for a great range of climate conditions and have been testedfrom −40 degrees Celsius to 150 degrees Celsius. The panels are alsonon-combustible, which provide fire resistance and heat resistance.

Referring to FIG. 2, there is shown an embodiment of the panel 10attached to a wall 40. As previously described, the panel has a supportlayer 12, which may include an aluminum honeycomb layer 22, a mid-layer14, which may be formed from a fiberglass sheet, and an outer layer 16,which may be formed from brick elements 18 and mortar-like or grout-likelines formed from a polymer 20.

The particular panel 10 shown in FIG. 2 has a first side 24 and a secondside 26, each side has a toothed shape, wherein a half-brick elementsize protrudes forming the teeth 32 with recesses 34 in between. Thetoothed shape 28 of the first side 24 is offset by one row of brick-likeelements from the toothed shape 30 of the second side 26. This allowsadjacent panels to be easily fitted together so as to maintain aconsistent laid brick pattern.

The panel 10 shown also has an upper straight side 36 and a lowerstraight side 38, thus allowing the panel to abut adjacent upper andlower panels. The upper and lower straight sides 36, 38 may also have alip formed from a protrusion of the support layer (and, optionally, themid-layer). The lip may meet with a corresponding lip of an upper orlower panel to form a channel between corresponding brick-like elements18, and the channel can be filled with a polymer similar or same as thepolymer 20 used in manufacture of the panel 10. These features andconstruction techniques allow for a continued and consistent appearanceor effect of the panels when forming a wall or other structure.

Also shown in FIG. 2 is a corner piece 42. It will be understood thatcorner pieces can be formed at a variety of angles to suit correspondingangles on a structure to which the panels are attached. In FIG. 2, thecorner piece 42 is shown as having an obtuse angle. In otherembodiments, the angle may be acute or a right angle (90 degrees).

Similarly to the panel 10, the corner piece 42 has a first side 44 witha toothed shape and a second side 46 with a toothed shape. The toothedshape of the first side 44 is offset from the toothed shape of thesecond side 46 by one brick-like row, such that the first side 44cooperates with the second side 26 of the panel 10, and the second side46 of the corner piece 42 can cooperate with a first side 24 of anotherpanel 10 (not shown). In these embodiments, the side edge of the supportlayer 12 and mid-layer 14 terminate at where each brick-like rowterminates, but variations are possible where the support layer 12 (andalso the middle layer 14 where appropriate extend further beyond orshort of where each brick-like row terminates, and will become apparentfrom a reading of the further embodiments.

FIG. 3 shows the panel 10 and the corner piece 42 joined together in aninstallation on a wall 40. The toothed shape 30 of the second side 26 ofthe panel 10 cooperates with the toothed shape of the first side 44 ofthe corner piece 42 so as to form a finger joint 48. The panel 10 andcorner piece 42 are formed so as to leave a gap 50 between the two,which may be filled with the mortar-like or grout-like polymer material20.

FIG. 4 shows a rear of a wall panel forming part of an embodiment of awall panel system 58 shown in FIG. 5 for attaching panels 10 to a wall.The system includes clips 52 which are affixed to the back of the panel10, and, in this embodiment, are affixed to the aluminum sheet 23 on theback of the honeycomb structure 22 in the support layer 12. Each clip 52has an upper hook 54 and a lower hook 56, which are designed tocooperate with a rail 60 (see FIG. 5).

The clip and rail system 58 for attaching panels to walls has a numberof advantages, including ease of installation. The clip and rail systemmay also provide an easily reversible installation, so panels 10 can beswapped out and in very readily.

FIG. 5 shows details of the clip and rail system 58 for attaching panelsto walls. In a typical installation process, the rails 60 are mounted tothe wall 40 and may also use a spacer 68. In this embodiment, the railsconsist of an upper bar 62 and a lower bar 64, which cooperate,respectively with the upper hook 54 and lower hook 56 of the clip 52.The rail 60 also has a back plate 66 which abuts the wall 40 or spacer68 and it can be affixed thereto using screws 70. The rails 60 and clips52 form an embodiment of the mounting system 58.

During installation, the clips 52 are moved towards the rails 60, suchthat the upper hook 54 is able to move over and towards the rear side ofthe upper bar 62, and the lower hook 56 is able to move over and towardsthe rear side of the lower bar 64. The panel 10 is then moved downwardlyso that the upper hook engages in a snug fit with the upper bar andlower hook engages in a snug fit with the lower bar.

Also shown in FIG. 5 is a rod or backer rod 71, which can be placedbetween panels 10 during installation. The rod may be formed from amaterial that allows for expansion and contraction of the panels invarying weather conditions. It should be understood that the rod is analternative to having lips on the panels as previously described. In aninstallation process, a rod 71 is placed between adjacent panels andthen the grout-like or mortar-like polymer 20 is placed between theadjacent panels and over the rod 71.

The rod 71 may also be formed of a material or to have structures, suchthat it keys into the grout-like or mortar-like polymer 20. This assistsin maintaining structural integrity of the installation.

FIG. 6 show two laterally adjacent panels 10 installed on a wall 40using the clip 52 and rail 60 of system 58. The panels 10 join togetherto form a finger joint 72, and in which there is formed a grout-like ormortar-like line 74 from a polymer at installation.

FIG. 6 shows that the rails 60 run continuously along the wall 40, whichprovides a consistent and straight line attachment point for all thepanels 10 along the rails. This can help to ameliorate or eliminate theeffect of defects in the wall 40, such as local or large curvatures inthe wall or unevenness of other kinds on the surface. The spacers 68used in cooperation with the clip and rail system 58 can be usedselectively to “pad out” the wall so that the rail 60 is able to form astraight edge. The spacers 68 can be formed from a material which isable to be sanded back or otherwise altered, which enables a fineradjustment of curvatures or other defects in the wall to provide astraight line when attaching the rail 60.

Although FIG. 6 shows only an upper and lower rail 60, it will beunderstood that the attachment system may have a greater number of railsto increase structural integrity of the panels. For example, having amid-rail in such an installation would help to prevent flexing towardsthe centre of the panel between the two rails shown in FIG. 6.

FIG. 7 shows panels 10A and 10B configured according to an alternateembodiment and an embodiment for joining two panels 10A and 10Btogether. In this embodiment, the left-most panel 10A is shown with afirst side 76 having a tooth pattern which is different from the toothpattern shown in previous embodiments of the corresponding side 24 ofpanels 10. In this regard, it will be noted that the tooth pattern ofthe side 76 has recesses 34 both at the top and bottom thereof. Asimilar tooth pattern appears at the side 78 of the right-most panel10B.

On the right side 78A of the left-most panel 10A, the support layer 12(and optionally the mid-layer 14) include a straight side 79 instead ofa tooth pattern as per the panel in FIG. 6. Instead of the toothpattern, the support layer 12 and mid-layer 14 at this side 78A of panel10A has spaces or gaps 82 corresponding to a half brick-like elementshape and size in alternating rows in the outer layer 16 of the panel10A. There is a corresponding pattern of spaces on the left-most side76A of the right-most panel 10B. The combined spaces 82, in thisembodiment, expose the mid-layer 14 in the panels 10A and 10B in theshape of a brick element.

During installation, the panels 10A and 10B are placed next to eachother such that their straight sides 79 directly abut, or can be spacedwith a rod 71. When in place, the corresponding half spaces 82 will forma full size brick-like element space, which can then be filled with aseparate brick-like element 84, which may also be made of porcelain. Theseparate brick-like element 84 may be the same as the brick-likeelements 18 in the panels 10A, 10B. Alternatively, to provide a specialstructural effect, the separate elements 84 can be of a different colourand/or texture, or could be of a different thickness, so as to provide avariation in the pattern of the structural appearance or effect producedby the panels.

When the panels 10A and 10B are installed, and the separate elements 84are affixed to the panel (this can be by use of a same or similar epoxyas used in manufacture of the panels), there will be left a gap 80forming a space for the grout-like or mortar-like line to be placedusing a polymer substance.

The panels, in other embodiments, may have spaces in the outer layer 16in different positions than those shown in FIG. 7. This can allowvariations of the appearance or effect according to aesthetic taste.

In another use scenario, it may be desired to end a panel installationat the end of a wall 40, or at an internal corner where it is desired topanel one wall adjacent the corner, but not the other wall adjacent thecorner. For example, if a wall 40 ends on a left side, then a panel suchas 10B can be used so that the left-most side 79 of the panel 10Bcorresponds with the end of the wall on its left side. In this scenario,the panel 10B will have a series of alternating spaces 82, whichcorrespond approximately to the size and shape of a half brick-likeelement 18. When the panel 10B is installed, the spaces 82 can be filledwith a separate half-size brick-like element so as to form a consistentappearance of the structural appearance or effect at the end of the wall40 in the panel 10B.

A corner piece 42 was detailed earlier with reference to FIGS. 2 and 3,in accordance with an embodiment. FIG. 8 shows another embodiment of acorner piece 100 in a panel system that may be suitable for use at awall corner having panels 10A and/or 10B affixed. The corner piece 100has a first side 101 and a second side 103. It will be understood thatthe corner piece 100 can be formed at a variety of angles to suitcorresponding angles on a structure to which panels are to be attached.In FIG. 8, the corner piece 100 is shown as having an obtuse angle. Inother embodiments, the angle may be acute or right angle (90 degrees).

The first side 101 of the corner piece 100 has a tooth-shaped pattern,including an outer layer 102 comprising a selected structuralappearance, in this case brick pieces which protrude 104, forming gaps110 therebetween. Similarly, the second side 103 of the corner piece 100has top layer brick elements, alternately protruding 104 so as to formgaps 110 therebetween. In this way, the corner piece 100 shown in FIG. 8is similar to the corner piece 42 depicted in FIGS. 2 and 3.

The corner piece 100 depicted in FIG. 8 also includes a support layer(not shown) which may be configured in accordance with the previouslydescribed support layer 12, and a mid- layer 105, wherein the mid-layer105 may be configured in accordance with the previously describedmid-layer 14 and allow for different thermal expansion and contractionrates of the support layer material and the outer layer material.

FIG. 9 is a detail of FIG. 8 towards the top of the corner piece 100.More-clearly shown in FIG. 9 is the configuration of brick elementscomprising the outer layer 102 wherein, in alternate rows, a brickelement has a half brick end 108 and a full brick end 106. The top-mostdepicted brick element has the full-length brick end 106 protrudingoutwardly from the second side 103 of the corner piece 100 and the halfbrick end 108 located on the first side 101 of the corner 100. The nextbrick row reverses the top brick row pattern, such that the brickelement half end 108 is located on the second side 103 of the corner100, and the full length brick end 106 is located on and protrudes fromthe first side 101 of the corner piece 100. The difference betweencorner piece 100 and that previously described is that the side edges ofthe corner piece 100 do not extend out with the protruding elements butfall short to form a straight line edge in alignment with the half-brickends 108.

Panels 10, 10A and 10B were described earlier, with reference to FIGS.1-7, in accordance with embodiments. FIG. 10 shows another embodiment ofa panel 120. Similarly to the embodiment of the panel 10, the panel 120in FIG. 10 includes a support layer 122 formed from a rigid material,and an outer layer 132 formed from a material different from the supportlayer material and comprising the selected structural appearance, which,in this case, is a stretcher bond brick pattern. The panel 120 alsoincludes a mid-layer 124 between the support layer 122 and the outerlayer 132, wherein the mid-layer 124 allows for different thermalexpansion and contraction rates of the support layer material and theouter layer material.

The panel 120 has a first side 125, which includes brick elements at anend of each alternate row of bricks that protrude 130 from an edge 136in alternate rows to form gaps 134 therebetween, such that theprotruding brick elements and the gaps form a tooth shaped pattern.

The second side 123 of panel 120 is shown with the top row of bricks,for example, having the end brick 129 set back from an edge 137 thesecond side 123. In the second row of bricks an end brick 131 on thesecond side 123 extends to the side line 137.

The alternate rows of bricks that protrude 131 from the second side 123of the panel 120 form gaps 126 between the bricks 131 which extend tothe side edge. In some embodiments, the surface of the gap 126 is formedfrom the mid-layer 124. In other embodiments, the surface of the gaps126 is formed from the support layer 122 of the panel 120.

It will be understood that, in the embodiment depicted in FIG. 10, thesides 125 and 123 are defined by where the support layer 122 or acombination of support layer 122 and the mid-layer 124 of the panel 120end. This panel 200 is thus similar to panel 10A depicted in FIG. 7,except the top end brick 129 on the second side 123 is set back insteadof protruding out, and likewise on the other side is protruding outinstead of set back.

FIG. 11 shows a panel system including a partially-depicted face of afirst panel 120A and a fully depicted face of a second panel 120B whichare configured according to the previously described panel 120. FIG. 11also shows a corner piece 100, as previously described and depicted inFIGS. 8 and 9.

It should be readily understood that when installing a panel system asshown in FIG. 11, an installer may first install the first panel 120A,and when the first panel is sufficiently secured, the installer can thenposition the second panel 120B for installation. The protruding brickelements 130 associated with the first side 125 of the second panel 120Bwill be located in the corresponding gaps 126 of the first panel 120A.

When the second panel 120B is sufficiently securely installed, theinstaller may then position the corner piece 100 for installation,wherein protruding brick elements 104 associated with the corner piece100 are positioned into the gaps 126 associated with the second side 123of the second panel 120B.

It will be understood by those skilled in the art that there may be manydifferent types of brick pattern that can be applied to embodiments ofthe panel, or the panel system in accordance with the present invention.The stretcher bond pattern of bricks is merely one example pattern usedto exemplify the present invention. It will also be understood that thetooth shaped pattern depicted at the first side 125 of the panel 120 inFIG. 10 may have a different kind of pattern to suit the brick layingpattern used on the panel.

Further, it is contemplated within the scope of the present inventionthat non-regular shape elements, such as rocks, could be used to formthe selected structural appearance for the outer layer of the panel. Insuch cases where the structural appearance is made from irregularlyshaped objects, it is possible to configure the first side 125 andsecond side 123 of the panel 200 so as to form joints between a firstpanel and a second panel which are adequately sealed. It will beunderstood that, though the pattern of the structural appearance may becomposed of irregular elements, the joints will include irregular shapedprotrusions on a first panel, with corresponding substantially sameirregular shaped gaps or spaces on a second panel.

FIG. 12 shows the rear face 150 of a panel 120 having the first side 125and the second side 123 reversed from the depictions in FIGS. 10 and 11.

The panel 120 of FIG. 12 is shown in use with another aspect of theinvention, being the means and method for sealing between panels.

The panel 120 may have attached around the sides of the support layer122 four sealing elements 152, including a top, bottom, first side, andsecond side sealing element 152. The sealing elements 152 will bedescribed in more detail in the description below relating to FIG. 13and FIG. 14.

In this embodiment, the sealing elements include brackets 153 forassisting in attaching each sealing element to a side edge of the panel200, which can comprise the support layer 122, or a combination of asupport layer 122 and mid-layer 124. In this embodiment, the brackets153 have an L-shaped cross-section, and may be affixed to the supportlayer 122 by screws 154.

FIG. 12 also shows positions 155 adapted to allow affixing of mountingbrackets for the panel to allow the panel to be mounted to a wall using,for example, rails as depicted by feature 60 in FIG. 6 for anotherembodiment of the invention.

FIG.13 shows a first panel 120C and a second panel 120D where, wheninstalled, panel 120C is located vertically above panel 120D. Each panelincludes a support layer 122, a mid-layer 124 and an outer layer 132.The outer layer 132 may be a brick or brick stretcher bond pattern aspreviously depicted in various embodiments.

Panel 120C has a sealing element 152 attached thereto via a bracket 153.The bracket has an L-shaped cross-section, with a first arm 156 of theL-shape abutting the rear face of the support layer 122 and a second arm158 of the L-shape abutting a side edge of the support layer 122. TheL-shaped bracket 153 may be affixed to the support layer 122 via anumber of screws 154 which in the embodiment shown are inserted into therear face of the support layer 122 but may equally be screwed into theside edge of the support layer 122.

Each sealing element (one sealing element located on panel 120C and theother corresponding sealing element located on panel 120D) includes apart 160 which may be formed from a sufficiently flexible, yetsufficiently durable material, such as rubber or a rubber-like compound.

Each sealing part 160 has a sealing surface 162. The sealing surfaces ofthe seal elements 152 may have a complementary shaping allowing thesealing surfaces of respective sealing parts 160 to meet and to form asufficiently water and wind resistant seal.

In the embodiment depicted in FIG. 13, for example, the shape of thesealing surface is sinusoidal or includes a sinusoidal-like curvedshape. The sinusoidal or sinusoidal-like curved shape extends forapproximately two sinusoidal or sinusoidal-like cycles on eachrespective sealing surface 162. In other embodiments, the sinusoidal orsinusoidal-like curve shape may include different integer or non-integersinusoidal or sinusoidal-like cycles. However, it will be appreciatedthat a greater number of sinusoidal or sinusoidal-like cycles mayproduce better precipitation and wind resistance, better noise andthermal resistance, and better structural integrity of objects to besealed.

FIG. 14 shows the two panels depicted in FIG. 13, 120C and 120D, movedtogether so that the respective sealing surfaces 162 of the sealingelements 152 meet with each other and form a seal 200.

In various other embodiments, the sealing surfaces 162 may have othertypes of periodic non-planar shapes, such as saw toothed shaped,square-wave shapes, and periodic shapes having peaks and troughs in theperiodicity, which are different from cycle to cycle. It will be readilyappreciated that a vast number of shapes are contemplated within thescope of the term “periodic non-planar shape.”

Although, in FIGS. 13 and 14, the seal elements are exemplified as beingattached to panels 120C and 120D, it will be appreciated that in othercircumstances a seal element may be attached to other objects orsurfaces in a building structure. For example, an installer may wish toinstall a bottom row of panels to form a wall structure, and a sealingelement 152 or row of sealing elements may be placed along a ground or afoundation (not shown) in order to form the bottom most seal of the wallstructure between the bottom line of panels and the ground orfoundation. Similarly, where panels are installed along a wall at a2-wall corner junction, a sealing element or row of sealing elements maybe placed along one of the walls in order to form the side seal of thewall structure between the side edge of panels mounted to the wallstructure and the other wall.

The invention is susceptible to variations, modifications and/oradditions other those specifically described, and yet it to beunderstood that the invention includes all such variations,modifications and/or additions, which fall within the scope of thefollowing claims.

Throughout this specification and the claims which follow, unless thecontext requires otherwise, the word “comprise”, and variations such as“comprises” and “comprising”, will be understood to imply the inclusionof a stated integer or step or group of integers or steps but not theexclusion of any other integer or step or group of integers or steps.

The reference to any prior art in this specification is not, and shouldnot be taken as, an acknowledgment or any form of suggestion that theprior art forms part of the common general knowledge.

1. A panel for providing a selected structural appearance, the panelcomprising: a support layer formed from a rigid material; an outer layercomprising elements which provide the selected structural appearance,the outer layer formed from a material different from the support layermaterial; and, a mid-layer between the support layer and the outerlayer, wherein the mid-layer comprises at least one sheet of materialselected to compensate for differences in thermal expansion andcontraction rates of the support layer material and the outer layermaterial, and wherein the support layer comprises a honeycomb substrate.2. The panel according to claim 1, wherein the support layer furthercomprises a backing sheet for the honeycomb substrate.
 3. The panelaccording to claim 2, wherein the backing sheet and honeycomb substrateare formed from aluminum.
 4. The panel according to claim 1, wherein theat least one sheet of material is a fiberglass sheet.
 5. The panelaccording to claim 1, wherein the at least one sheet of material is analuminum sheet.
 6. The panel according to claim 1, wherein the selectedstructural appearance comprises a plurality of regular shaped elementshaving a periodic tessellated pattern.
 7. (canceled)
 8. (canceled) 9.The panel according to claim 1, wherein two opposing sides of the panelcomprise complementary toothed shapes such that, when one panel isplaced next to another like panel the shape of adjacent sides of thepanels form a finger joint to provide a continued alternating off-setrow brick pattern.
 10. The panel according to claim 9, wherein the panelis configured so that the finger joint comprises a gap, wherein the gapis adapted to be fillable to produce a grout-like or mortar-like line.11. (canceled)
 12. The panel of claim 6, wherein a first side of thepanel comprises at least one row where at least a part of an end elementof the row protrudes outwardly, and at a second side of the panelopposite the first side, an end element of the row forms a part elementspace, such that, when two panels are to be placed side-by-side, theprotruding end element of one panel is to be placed in the correspondingpart element space of the other panel.
 13. The panel according to claim12, wherein alternating rows of elements include at least a part of anend element of each row protruding outwardly of the first side, and anend element of each row forming a part element space, wherein at thefirst side of the panel the support layer is shaped to correspond withthe end elements of each row.
 14. (canceled)
 15. (canceled) 16.(canceled)
 17. The panel of claim 6, wherein alternating rows ofelements include at least a part of an end element of each rowprotruding outwardly of the first side, and an end element of each rowforming a part element space, wherein the support layer includes astraight side edge along at least one side of the panel which is alignedwith an outer edge of the end elements that protrude outwardly of theside, thereby exposing the support layer in each of the part elementspaces.
 18. (canceled)
 19. The panel according to claim 17, wherein afirst side of the panel includes the support layer having a straightside edge aligned with an outer edge of the end elements that protrudeoutwardly of the first side, and a second side of the panel includes asupport layer having a straight side edge aligned with an outer edge ofthe end elements that form a part element space such that the endelements which protrude outwardly of the second side protrude beyond thesupport layer straight side edge.
 20. (canceled)
 21. (canceled) 22.(canceled)
 23. (canceled)
 24. (canceled)
 25. (canceled)
 26. (canceled)27. The panel according to claim 6, wherein the pattern includes agrout-like or mortar-like line between each of the elements. 28.(canceled)
 29. (canceled)
 30. (canceled)
 31. (canceled)
 32. (canceled)33. The panel of claim 1, further comprising a sealing element adaptedto be fixed to at least one side of the panel, and so as to present asealing surface outwardly facing with respect to the panel, wherein thesealing surface has a periodic non-planar shape.
 34. The sealing elementaccording to claim 33, wherein the periodic non-planar shape is asinusoidal or sinusoidal-like curved shape.
 35. (canceled) 36.(canceled)
 37. (canceled)
 38. The sealing element according to claim 33,further comprising a bracket for fixing the sealing element to anobject.
 39. (canceled)
 40. (canceled)
 41. The sealing element accordingto claim 33, wherein at least a part of the sealing element is formedfrom a rubber or rubber-like compound.
 42. A panel system, comprising: afirst panel; and a second panel; wherein each of the first panel andsecond panel comprises: a support layer formed from a rigid material,the support layer comprising a honeycomb substrate, an outer layerformed from a material different from the support layer material, theouter layer comprising elements that provide a selected structuralappearance, the selected structural appearance comprising a plurality ofregular shaped elements having a periodic tessellated pattern, and amid-layer between the support layer and the outer layer, wherein themid-layer comprises at least one sheet of material selected tocompensate for differences in thermal expansion and contraction rates ofthe support layer material and the outer layer material; wherein, foreach of the first panel and second panel, the outer layer comprises atleast one row of elements, wherein at least a part of an end element ofthe at least one row protrudes outwardly of a first side of the panel,and wherein an end element of the at least one row forms a part elementspace at a second side of the panel opposite the first side.
 43. Thepanel system of claim 42, wherein, for each of the first panel andsecond panel, the outer layer comprises rows of elements, wherein onalternating rows at least a part of an end element of each row protrudesoutwardly of the first side of the panel, wherein an end element of eachrow forms a part element space, wherein at the first side of the panelthe support layer is shaped to correspond with the end elements of eachrow, and wherein when the first panel and second panel are placedside-by-side at least one protruding end element of one panel is placedin the corresponding part element space of the other panel to form afinger joint.
 44. The panel system of claim 42, wherein, for each of thefirst panel and second panel, the outer layer comprises rows ofelements, wherein on alternating rows at least a part of an end elementof each row protrudes outwardly of the first side of the panel, whereinan end element of each row forms a part element space, wherein thesupport layer includes a straight side edge along at least the firstside of the panel that is aligned with an outer edge of the end elementsthat protrude outwardly of the first side of the panel, thereby exposingthe support layer in each of the part element spaces at the first sideof the panel.
 45. The panel system of claim 44, wherein when the twopanels are placed side-by-side so as to cause abutment between thestraight side edges of the panels, end elements in alternate rows ofeach panel form two adjacent part element spaces to accommodate aseparate element that substantially corresponds to a size and shape ofthe adjacent part element spaces such that the separate element spansacross adjacent panels when affixed to the exposed support layer. 46.The panel system of claim 45, further comprising one or more separateelements for affixing to the exposed support layer across the adjacentfirst and second panels.
 47. The panel system of claim 44, wherein, foreach of the first panel and second panel, the support layer includes astraight side edge along the second side of the panel that is alignedwith an outer edge of the end elements that form the part element spacesat the second side, wherein the end elements that protrude outwardly ofthe second side of the panel protrude beyond the support layer straightside edge along the second side, wherein when the first panel and secondpanel are placed side-by-side the protruding end element of one panelthat extends beyond the support layer straight side edge is placed inthe corresponding part element space of the other panel and affixed tothe exposed support layer to form a finger joint.
 48. The panel systemof claim 42, further comprising one or more rails for attachment to asurface to be paneled, wherein the panels include clips for attachmentto the one or more rails.
 49. The panel system of claim 42, furthercomprising one or more backer rods for placement between adjacentpanels, the backer rods having a shape and size to maintain a selectedseparation between the adjacent panels.